Welcome to the Reliability

Solutions Webinar
We will begin momentarily!

Managing Your Assets with PeakVue™

Plus Actionable Diagnostics
Presenters:
Scott Bassett – Scott.Bassett@Emerson.com
Michael Szurkowski – Michael.Szurkowski@emerson.com

Asad Malik – Asad.Malik@Emerson.com

Safety Moment: Stay Physically Active During Self-Quarantine
In many states, fitness centers remain temporarily closed
Sedentary behavior and low levels of physical activity can have negative effects on the health,
well-being and quality of life
Self-quarantine can also cause additional stress and challenge your mental health

Physical activity and relaxation techniques can be valuable tools to help you remain calm and
continue to protect your health during this time
– Take short active breaks during the day
– Put time on your calendar to exercise
– Deep or Belly Breathing

Stay Home, Stay Safe, Stay Physically Active

 Presenters

Scott Bassett Michael Szurkowski

ISO Cat IV Vibration Analyst ISO Cat III Vibration Analyst

Sales Enablement Business Development / SME
Been with Emerson 7 yrs. Been with Emerson 16 yrs.
Previously an analyst in paper industry Previously an analyst in power industry

Emerson Confidential 3
 Vibration Measurement
Mils,IPS, G-s
Acceleration
A (high freq.)
M
P
L
I
Velocity
T (general purpose)
U
D
E Displacement
SPEED (frequency in Hz, RPM or CPM) (low freq.)

Emerson Confidential 4
 Vibration Measurement
Mils,IPS, G-s
• Vibration data is usually rich in information
A Typical vibration data
M is looking for
P
L
Specific Events
I that happen at specific
T Frequencies within a
U frequency range.
D
E
SPEED (frequency in Hz, RPM or CPM)

Emerson Confidential 5
PeakVue
What is PeakVue?

PeakVue is Emerson’s patented method of separating very

high frequency, short duration stress waves from regular
vibration data.

In layman’s terms, it detects impacting.

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 Why Monitor with PeakVue?

Emerson Confidential 8
 How is PeakVue different?
Amplitude

Late-Stage
Vibration
Failure Mode

Early Stage Mid-Stage

Vibration Vibration
Time 9
 How is PeakVue different?
PeakVue
Tracks/Trends
Late-Stage
Machine
Problems
5
1 2 3 4
Amplitude

PeakVue
Tracks/Trends Late-Stage
Mid-Stage Vibration
PeakVue Identifies
Machine Failure Mode
Early-Stage
Machine Problems
Problems
Early Stage Mid-Stage
Vibration Vibration
Time 10
 What are Stress Waves?

Emerson Confidential NOTE: The speed of sound (c) in most metals ranges from approximately 5000 to 10,000 ft/sec (1520 to 3040 m/sec). 11
 What are Stress Waves?
• Stress Waves are generated due to
- Impacting, fatigue cracking, scoring, scuffing, abrasion, friction, etc.

• Stress Wave emissions are typically very short term

- Lasting several microseconds to a few milliseconds.
- Normal sampling rates will not detect stress waves.

• High Frequency 1000 – 15000 Hz

- Dependent on the mass & geometry of impacting object.
- A larger roller will result in lower frequencies

Balls or Rollers

Stress Waves

Outer Race Outer Race Defect

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How does PeakVue work?

This diagram shows sampling of data using PeakVue data collection.

Impact - is captured with

PeakVue sampling

PeakVue Samples

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 PeakVue provides EARLY Warning

PeakVue uses High Sampling Rates

(Typically 50 to 100 Ksamples/second)

Identifies bearing, gear or impacting problems months or years before failure.

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PeakVue Sampling and Filtering
This oversimplified example indicates how PeakVue data is collected and stored.

PeakVue Sampling Rate

Vibration Data
collection/storage Rate
PeakVue Sampled Data
PeakVue
Stored Data

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PeakVue Filter

Correct filter?

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 PeakVue High Pass Filter
Amplitude

PeakVue
Velocity Vibration PeakVue High Pass Filter
Data
Data 1000Hz
1000 HztoHP
80KFilter
Hz

SPEED (frequency in Hz, RPM or CPM)

Emerson Confidential 17
 PeakVue High Pass Filter
Amplitude

Velocity Vibration PeakVue Band Pass Filter

Band Pass Data
Data Between 100
100-600 Hz – 600 Hz
BP Filter

SPEED (frequency in Hz, RPM or CPM)

Emerson Confidential 18
 Guidelines for Application of Filters
Filter Filter
Application Application
(Hz) (Hz)
500 Low speed machines having gear mesh < 125 Hz. Bearing 20-150 Low speed machines having gear mesh < 125 Hz.
and gear problems Bearing and gear problems
1,000 Intermediate speed machinery (<2000 RPM) with gear mesh 50-300 Intermediate speed machinery (<2000 RPM) with gear mesh
<300 Hz. <300 Hz.
2,000 Medium speed machinery (<4000 RPM) with gear mesh < 600 100-600 Medium speed machinery (<4000 RPM) with gear mesh <
Hz. 600 Hz.
5,000 Machinery up to 9000 RPM and gear mesh <1500 Hz. 500-1000 Machinery up to 9000 RPM and gear mesh <1500 Hz.
Required attention be paid to how the sensor is mounted as Required attention be paid to how the sensor is mounted as
well as the sensor’s frequency response. well as the sensor’s frequency response.
10,000 High speed machinery with gear mesh <3000Hz.
Sensor must be permanently mounted with frequency
response of 3 dB in the 30 kHz or higher range.
20,000 High speed machinery with gear mesh <6000Hz.
Sensor must be “high frequency’ and permanently mounted.

Tip: Bandpass for excitation of structural resonance (e.g. gear mesh)

Emerson Confidential High Pass to detect metal-on-metal impacting or fatigue cracking 19
 Measurements Comparisons
Features
Severity Values
(meaningful & interpretable)
Waveform
(shows actual impacting)
Spectrum
Sensor
Measurement
Slow Speed Measurement
Variable Speed (VFD)
Pervasive Sensing
Enveloping
G’s values may decrease as failure
becomes imminent.
Four or five averages to process spectrum
using low-pass filter. Effective early fault
identification.
Standard accelerometer
Signal is band-pass filtered, rectified & 2.5K
– 5K Hz envelop filtered.
Slow-speeds may limit modulation of the
defect frequencies below 2.5k Hz
Four or five averages to process spectrum;
limits use for variable speed measurements.
No Pervasive Sensing capability.
Demodulation
G’s fault severity difficult to determine.
Measures average not peak value.
Does not show true impact amplitude.
Anti-aliasing FFT filter. Spectral data may
have broad-band noise floor from machine
resonance.
Standard accelerometer
Signal sampled at 2.56xFmax, amplified &
low-pass filtered. Amplitude dependent on
event duration & filter setting.
Slow-speeds may limit modulation of the
defect frequencies for fault amplitudes.
Not trend-able on variable speed
machines.
No Pervasive Sensing capability.
PeakVue
G-s trend values will increase as fault gets
worse.
Waveform true amplitude in G-s & Impact
pattern
Spectral defect peaks & fault frequencies.
Reduced noise floor.
Standard accelerometer.
Oversampled at 50-100Ksamples/sec.
High-pass or Band-pass filter.
Typically measures from 1KHz-40KHz.
Measures down to 0.5 RPM
PeakVue severity will be maintained through
various speeds. Order Tracking capable.
Autocorrelation / PeakVue Plus distinguishes
between mechanical & lubrication faults.
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 The Waveform is Key
Outer Race Defect Rolling Element Defect
1. Amplitude information is only
retained in the waveform.
88% 98%
2. Must look at waveform only
for severity information. Max Waveform = 30.9 g’s Max Spectrum = 0.5 g’s

Cracked Inner Race Gear Defect

3. Amplitude loss in the spectrum
varies from 85-99%!
95% 97%
4. Even with clear impacting
(e.g. Rolling Element Defect)
amplitude can drop by 98%.
Inner Race Defect Lubrication Fault
5. Lubrication defects
(e.g. random impacting) drop
most severely – up to 99%+. 96% 99%

Max Waveform = 19 g’s Max Spectrum = 0.8 g’s

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Trending the Max Amplitude in the Waveform
• The key indicator of severity is the Max Amplitude in the PeakVue waveform.
• Unlike vibration, this value is monotone increasing.
• Rate of increase indicates stage of bearing wear.
• Near vertical trend line indicates bearing is about to wipe.

30 day PeakVue Trend vs. Bearing Failure Stage

Stage 1
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 PeakVue Route Set-up for the AMS 2140
AMS 2140 automatically
HP Filter ≥ locates maximum peak in the
Fmax waveform

Set up

Single
Average

010 – DRAG-LOW SPEED

Trend of “MP Wave”
DRAG#1 -MD INTERM SHAFT #2 DRUM END
shows fault severity

Peak Acceleration in G-s

Parameter Type:
MP Wave

Days: 25-JUL-19 To 23-OCT-19 23

Autocorrelation
Autocorrelation

What is autocorrelation and why would we use it?

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Autocorrelated PeakVue Waveform

Non Periodic Periodic

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PeakVue data with bearing outer race defects marked

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PeakVue autocorrelated waveform has a 86.5 Hz period from a bearing
outer race defect.

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PeakVue autocorrelated waveform with bearing outer race defect.
If the amplitude of the
periodic event is
somewhere between zero
and one, the square root
of the peak amplitude will
be the approximate
percentage of energy
contributed by the fault
with that period.

The periodic events that

are present in the
waveform, are the events
that will be seen in the
Square root of .849 is .92 or 92% of the energy PeakVue spectrum.
(about 20.5 of the 22.35 G’s in the waveform)
is generated by the outer race fault.
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PeakVue
Severity Calculations
 PeakVue Alert Level:
Periodic Data Collection
When monitoring machines infrequently, the alert level needs to be conservative to ensure that you
catch a defect prior to failure.

This table provides a Guideline for suggested alert levels.

The fault level is normally set at twice this value.
(Keep in mind that these are the levels
after the autocorrelation calculations are performed)
Recommended PeakVue Alerts Level
For use with Portable Data Collectors
Speed (RPM) versus g’s peak

Emerson Confidential 31
 Rule of 10’s for Automated Collection on Common Assets
With Automated Data Collection, readings are typically updated at least once per hour.
Therefore, alert level can be set higher.

A good rule of thumb for most process equipment with turning speeds between 900 and 4000 RPM
is called the “Rule of 10’s”.

PeakVue Interpretation
(reading in g’s peak)

10 Some Issue
20 Serious problem
40 Action Point

PeakVue on YouTube PeakVue Homepage

Emerson Confidential 32
PeakVue Plus
PeakVue Plus Analytics

High

Lubrication Bearing Defect

(Advanced)
PeakVue

Good Machine Bearing Defect

(Early)
Low

Low High
Periodicity
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 PeakVue Plus – Bearing Fault Severity
Below is an example of how PeakVue Plus performs it’s calculation

( )
∗ % ℎ
( )

In this example, our max PeakVue waveform

is 20 g’s. The Fault limit is 12 g’s
And the % of the energy is 14
(20/12) * .14 = .233

The fault severity graph uses 80 as @ 100%

of fault level
.233 * 80 = 18.6

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PeakVue Plus – Lubrication Severity

Non-periodic energy

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 PeakVue Plus in AMS 2140
PeakVue: Periodicity: End User Screen:
Signature technology Shows nature of impacting:
+ Detects impacting • Mechanical (bearing/gear)
+ Confirms good operation • Random (lubrication)
+ Early warning about developing
faults
+ Increase with severity

Bearing failure can be attributed to

Shows Information –
lubrication issues
https://www.machinerylubrication.com/Read/967/lubrication-failure
Not Data
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PeakVue Plus
Case Histories
Case Study #1 - Vacuum Pump Gearbox
Bearing fault measurement point G*1

Input speed 1195 RPM, 15 tooth pinion, 75 tooth bull gear, Output speed at 239 RPM

Input bearing reported as defective.

Customer sees about 4 g’s and calls a fault for this application at that level

Output Shaft
~240 RPM
MHM G*2 MHM G*4
TEAC CH5 TEAC CH6

MHM G*7
EAC CH8

Externally
Powered 15 teeth 75 Teeth MHM G*6
TEAC CH7
Fan

Laser Tach
MHM G*5
TEAC CH1
TEAC CH4 MHM G*3
Input Shaft TEAC CH3
MHM G*1
1195 RPM TEAC CH2 39
Vacuum Pump Gearbox

PeakVue spectral data PeakVue waveform data

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Vacuum Pump Gearbox

PeakVue Plus configuration screen PeakVue Plus results

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Vacuum Pump Gearbox

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Case Study #2 - Ash Sluice Water Pump

Outboard bearing location on pump. This is the thrust bearing.

Bearing is an SKF 7315 BECBM

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Ash Sluice Water Pump

PeakVue spectral data PeakVue waveform data

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Ash Sluice Water Pump

PeakVue Plus configuration screen PeakVue Plus results

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Ash Sluice Water Pump

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AMS Asset Monitoring Training Courses - Path to Success Approach

Emerson Training and Certification Path

https://www.emerson.com/en-us/automation/services-consulting/educational-services/ams-training 47
 Summary
• Emerson has made PeakVue an integral part of our monitoring systems. Include
PeakVue monitoring and PeakVue Plus pervasive sensing on all your machines
in your Reliability program.
• Attend a PeakVue & Autocorrelation training class.
• Contact Guardian Support or Local Emerson Impact Partner for the latest
version of the AMS 2140 firmware that includes PeakVue Plus.

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 Please Join Us for Remote Asset Monitoring Solutions Webinar series
To help protect your priv acy, PowerPoint has blocked automatic download of this picture.

Webinar #1: Edge Analytics for Automated Monitoring of Assets Remotely

WEDNESDAY, APRIL 29, 2020
9 a.m. CT – Austin | 3 p.m. – London | 6 p.m. – Dubai | 10 p.m. – Singapore / Manila

Webinar #2: Utilizing IIoT Wireless Vibration Solutions to monitor Your Assets
WEDNESDAY, MAY 6, 2020
9 a.m. CT – Austin | 3 p.m. – London | 6 p.m. – Dubai | 10 p.m. – Singapore / Manila

Webinar #3: Integrating Solutions to Enable Remote Monitoring

WEDNESDAY, MAY 13, 2020
9 a.m. CT – Austin | 3 p.m. – London | 6 p.m. – Dubai | 10 p.m. – Singapore / Manila

For registration, contact Emerson Impact Partner or Asad.Malik@Emerson.com

Emerson Confidential 49